Combustion engineering and gas utilization

908 Pages·2013·32.251 MB·English

by  Cornforth, J. R.

Combustion Engineering and Gas Utilisation
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Combustion Engineering
and Gas Utilisation
BRITISH GAS SCHOOL OF FUEL MANAGEMENT
Editor: J R Cornforth, SSe, CEng, MIMeehE. FlnstE. FIGasE.
British Gas-
~~o~;~~n~~~up
LONDON AND NEW YORK
Published by British Gas pic
Rivermill House, 152 Grosvenor Road, London SW1V 3JL
First published 1992 by E & FN Spon
Published 2013 by Routledge
2 Park Square, Milton Park, Abingdon, Oxon OX14 4RN
711 Third Avenue, New York, NY 10017
Rout/edge is an imprint of the Tay/or & Francis Group, an informa business
First edition 1970
Third edition 1992
© 1992 British Gas pic
Typeset in Great Britain by The College of Fuel
Technology, London
ISBN 041.9176705
Apart from any fair dealing for the purposes of research or
private study, or criticism or review, as permitted under the UK
Copyrights Design and Patents Act, 1988, thi:; publication may
not be reproduced, stored, or transmitted, in any form or by
any means, without the prior permission in writing of the
publishers, or in the case of reprographic reproduction only
in accordance with the terms of the licences issued by the
Copyright Licensing Agency in the UK, or in accordance with
the terms of the licences issued by the appropriate Reproduction
Rights Organization outside the UK. Enquiries concerning repro
duction outside the terms stated here should be sent to the
publishers at the London address printed on this page.
The publisher makes no representations, express or implied,
with regard to the accuracy of the information contained in this
book and cannot accept any legal responsibility or liability for
any errors or omissions that may be made_
A catalogue record for this book is available from the British
Library
Library of Congress Cataloging-in-Publication data available.
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Foreword
This is the third edition of 'Combustion Engineering and Gas Utilisation' and I am pleased to have
the opportunity to contribute a foreword to a publication that has clearly established itself as an
essential work for study and reference. That it is produced by the British Gas School of Fuel
Management is not only a tribute to the expertise and commitment of the School's staff but should
re-assure those concerned with gas utilisation that the School continues its world-leading work in
energy efficiency. This has become so much more important as we recognise the fundamental role
of energy efficiency in meeting environmental challenges.
This book offers a comprehensive source of reference on all aspects of gas utilisation in the
industrial, commercial and administrative market sectors. It covers process, space-heating and hot
water equipment in detail, Codes of Practice and Standards and the important issue of fuel
efficiency.
In commending it to a wide readership, I am conscious of the success of the two previous editions,
which attracted a world-wide usage among gas undertakings and academic institutions. I am certain
that it will continue as a valued work for reference and education in the gas industry.
Mr R Evans
Chairman and Chief Executive, British Gas pic
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Contents
Foreword v
Preface ix
Contributors xi
Chapter One: COMBUSTION 1
Gaseous fuels, Combustion of natural gas, Flame properties and structure, Combustion performance,
Furnace and protective atmospheres, Oxygen in combustion process, Combustion of fuel oils, References.
Chapter Two: GAS BURNERS AND BURNER SYSTEMS 37
Interchangeability of gases, Diffusion flame burners, Atmospheric aerated burners, Air blast burners,
Nozzle mix burners, Radiant burners, Recuperative nozzle mixing burners, Radiant tube burners,
High temperature regenerative burners, Immersion tube burners for liquid heating,
Specialised types of gas burners, Oxygen enrichment techniques for gas burners, Pilot burners,
Working flame burners, References.
Chapter Three: MULTI FUEL BURNERS 93
Multifuel systems, Design principles, Burner characteristics and performance, Triple-fuel firing,
References.
Chapter Four: FLOW OF FLUIDS 115
Terms and definitions, The effects of temperature and pressure on fluid volume, Hydrostatics,
Mechanics of fluid flow, Friction, Calculations of pressure losses, References.
Chapter Five: HEAT TRANSFER 155
Conduction, Convection, Radiation, Heat transfer in practice, References.
Chapter Six: GAS UTILISATION EQUIPMENT 195
Space heating, Hot water services, Industrial liquid heating, Hot water, steam and thermal fluid boilers,
Drying, Glass, Ceramics and clay, Metal heating, Metal re-heating, Metal melting, Incineration;
Atmosphere generation, Catering, Baking ovens, Air conditioning, References.
Chapter Seven: WASTE HEAT RECOVERY 427
General design considerations, Heat exchange, Direct heat recovery. Liquid to liquid heat exchange,
Gas to gas heat exchange, Gas to liquid heat exchange, Methods which upgrade recovered heat,
Systems applications, References.
Chapter Eight: REFRACTORY AND INSULATING MATERIALS IN FURNACE
CONSTRUCTION 501
Furnace refractories, Furnace construction, References.
Chapter Nine: GAS AND AI R SUPPLY CONTROLS 523
Governors, Manually operated valves, Safety shut off valves. Safety shut off valve systems,
Pressure and flow safeguards, Air/gas ratio and throughput control, Typical gas control systems,
References.
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Chapter Ten: IGNITION AND COMBUSTION SAFEGUARDS 627
Start flames and pilot burners, Basic ignition procedure for industrial gas equipment,
Shut down, Combustion safeguards - general, Manual, semi-automatic and fully automatic burner light up,
monitoring and shut down, References.
Chapter Eleven: PROCESS CONTROL 665
Process control theory, Automatic controllers, Temperature Measurement, Control valves and actuators.
Chapter Twelve: SITE SUPPLY AND INTERNAL INSTALLATION 703
Site supply, Internal installation, Vents, Installation requirements, Installation practice, References.
Chapter Thirteen: POWER PRODUCTION FROM GAS 729
Total energy, Prime movers, Small scale combined heat and power (CHP) systems
Large scale combined heat and power (CHP) systems, CHP systems for direct-drive applications
Gas engine driven heat pumps, Mechanical vapour recompression, Fuel cells,
Thermo-electric and thermionic electricity generation, Magneto-hydrodynamic generation, References.
Chapter Fourteen: INSTRUMENTATION AND MEASUREMENT 771
Temperature measurement, Pressure measurement, Flow metering, Combustion products analysis,
Humidity and dewpoint measurement, Computerised energy monitoring systems, References.
Appendix: SI UNITS AND CONVERSIONS 853
SI basics, Symbols in the book, Variants from standards, Conversion factors, References.
Index 877
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Preface
Since the second edition of this handbook was published in 1983, a whole range of new efficient gas
fired space, water and process heating equipment has appeared on the industrial and commercial
market. Also 8ritish Gas has been privatised and many new Standards, Codes of Practice and
Regulations have been introduced. This publication attempts to bring engineers up to date with
equipment currently available and sound combustion engineering principles and practice.
In addition, the importance of correct installation, commissioning, servicing and maintenance of gas
utilisation equipment for safety and efficiency cannot be stressed too strongly. It is important that
only competent and trained staff are employed in such activities. All operators should be aware of
the safe light up, shut down and emergency isolation procedures.
The installation of pipework should conform to the Gas Safety (Installation and Use) Regulations
1984 and also to British Gas Publication IM/16, Guidance Notes on the Installation of Pipework in
Customer's Premises. Before gas fired equipment is brought into production for the first time it
should be properly commissioned, as in the Guide to Commissioning Procedures for Gas Fired Plant
document which is being prepared by the Institution of Gas Engineers.
Gas fired plant requires regular attention throughout its life in order to ensure safe and efficient
operation. Planned maintenance is therefore essential in order to extend the useful life of compo
nents and prevent where possible breakdowns during production periods.
Additionally, wear and tear on mechanically moving parts means that over a period of time pressure
settings, air gas ratios and !Iue gas analyses may tend to drift from their original setting resu Iting in
loss of efficiency and perhaps a reduction in the safety margin employed. For this reason then, it
will usually be more economic as well as good practice to regularly inspect and maintain gas fired
equipment. Appliances must not be used if they are unsafe in any respect.
The frequency of servicing will be determined by the type of equipment employed, period of use,
the environment in which it is installed and the degree of reliability expected. In practice whilst
many tests can be carried out annually, there will be some checking which should be done
quarterly, weekly or even daily, in order to maintain optimum efficiency and safety. All new
equipment should be supplied with a service manual giving an extensive guide to servicing
requirements but older equipment should be serviced using sound engineering practice and
judgement.
J. R. CORNFORTH
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